Co-disposal pollution control method-II

ABSTRACT

Process for disposal of a waste ash by addition thereto of sodium salts, preferably sodium sulfur oxide salt Na 2  SO x  where x is 3 and/or 4, in an amount ranging from 5-85 weight percent (dry basis) and adjusting the water percentage to within the range of 6-35%, preferably 15-28%. The coefficient of permeability of the ash and sodium salt is reduced from 10 2  cm/sec to the &#34;impermeable&#34; standard of 10 -6  and below. The preferred mixes also call for a smectite clay additive present in the range of from 0.1% to 5%. A flocculant in amounts of 0.01% to 1% can be substituted for about 3-5% of the water content. A principal source of the Ma 2  SO x  is sodium FGD waste, preferably from the use of Nahcolite (a natural mineral form of sodium bicarbonate) as an SO x  sorbent in the Nahcolite FGC process. The resulting co-disposal process simultaneously renders the highly soluble Na 2  SO x  (10 2  g/L) an ash impermeable, and suitable for geomorphologically stable landfill disposal by known techniques to heights in excess of 200&#39;. Any waste ash may be used, for example, municipal or industrial incinerator ash, fly ash and/or bottom ash from industrial or power plants burning fossil fuels for steam or eneryg, or scrubber sludges. The scrubber sludge may be from sodium or calcium sorbent scrubbers and may contain fly ash and/or bottom ash. Waste ash sources may be mixed and disposed by the process.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of our co-pending application Ser. No. 06/874,622, filed June 16, 1986 entitled CO-DISPOSAL POLLUTION CONTROL METHOD; now U.S. Pat. No. 4,726,710, issued Feb. 23, 1988. The portion of the term of any patent(s) issued on the present application extending beyond the expiration of said U.S. Pat. No. 4,726,710 on Feb. 23, 2005 is hereby disclaimed. This application is directed to disposal of ash and ash-containing wastes other than solid ash wastes from combustion of fossil fuels such as coal and oil.

FIELD

This application relates to the disposal of solid ash and/or ash-containing wastes from combustion of fossil and non-fossil fuels or burnable materials, and more particularly to the disposal of fly ash and bottom ash from industrial boilers and power plant furnaces, municipal or industrial incinerator ash, any type of waste ash, and scrubber sludge containing ash components (herein "waste ash" generically). It has been discovered that the use of sodium sulfate, alone or in a mixture with montmorillonite smectite clays and/or various flocculants as minor additives, seals the waste ash making it impermeable, within accepted industry standards, as determined by accelerated leakage tests.

BACKGROUND

In 1984 (the most recent year data is available), power production at U.S. utility plants resulted in about 80 million tons of solid waste of which an estimated 72-76 million tons was produced from coal and oil combustion. Of the latter, about 53 million tons was fly ash from coal combustion, 19 million tons was bottom ash, and 5 million tons was sludge from flue gas scrubbers. This sludge contains some ash component, and is predominantly calcium scrubber sludge containing ash, CaSO₄, CaSO₃ and water.

About 75% of this utility solid waste is disposed in landfills or surface impoundments, with only 25% being used as construction or road building material. Utilities operate over 1,000 waste disposal facilities, at a cost of around $800 million per year. By the year 2000, the total of fly ash, bottom ash and FGD sludge wastes is expected to increase to about 125-150 million TPY. Further, because of the expected more stringent regulations for landfills and more extensive groundwater monitoring, the disposal costs are expected to double.

Added to this enormous disposal burden is waste ash from municipal, industrial, institutional and private incinerators, e.g. trash incinerators from which energy may or may not be generated. This ash is currently estimated at from 10 to 20 million TPY for municipal incinerator alone.

Examples of typical coal ash constituents are found in the Coal Ash Disposal Manual, 2d Ed., Final Report Oct. 1981, CS2049 Research Project 1685-3 by GAI Consultants Inc. for the Electric Power Research Institute, Palo Alto, Calif., and in U.S. Pat. No. 3,962,080. These references report that inorganic compounds of Si, Al, Fe, Ti, Ca and Mg comprise over 90% of coal ash in the form of unburned mineral matter (rock). But the focus is on toxic trace amounts of heavy metals (such as B, Ba, Be, Pb, Co, Cu, Cd, Cr, Zn, Zr, Se, Sn, and As), naturally occurring radionuclides (principally Ra²²⁶, Ra²²⁸ /Th²²⁸, Th²³⁰ and Th²³²), and organics such as polycyclic aromatic hydrocarbons (PAH's) that are part of the residual (unburned) fuel carbon. The fly ash and bottom ash are essentially indistinguishable, in that both contain these toxic components, whether the ash is collected wet (bottom ash in sumps or fly ash in scrubbers) or dry (fly ash in baghouses or ESPs).

Incinerator ash similarly contains toxics, although the distribution may vary widely. For example, disposal of spent batteries, electronic goods, paint (containing metal oxide pigments), and other sophisticated items of modern society can result in incinerator ash with extraordinarily high content of Pb, As and Zn, and others such as Hg, Se, Cr, Co, Ba, Ti, and the like.

The present methods of disposal of waste ash components in open ponds or landfills permit slurry water, rain or ground water to leach those toxic elements from them and allows the elements to migrate into the ground water. This is particularly the case where the leaching water contains natural, or ordinarily present, chemicals (e.g. acid rain, or acid or caustic sludges) which tend to accelerate leaching. In view of the hazards involved with such toxic trace elements or PAH's entering the groundwater, the utility and incinerator industry and governmental bodies are researching the leachability of ash and sludge wastes. All involved and affected parties are vitally interested in methods of inhibiting leach water migration, such as by the use of pond and landfill bottom and top liners.

Still another concern in the utility and incinerator industry involves desulfurization of flue gas using reactive sorbents to remove sulfur oxide compounds from the flue gases to meet EPA emission standards. For example, 60-70% of the sulfur in low sulfur Montana coal (containing about 0.5% total S) must be removed to achieve compliance. There is also impetus for better FGD processes. This impetus is derived from the growing concern over acid rain problems traceable to stack gas SO_(x) emissions. Currently, the principal FGD process involves wet limestone scrubbing which results in approximately 5 million TPY of disposable calcium sulfate scrubber sludge. Less than 1% of this sludge is utilized in any meaningful fashion (typically for gypsum-type wallboard). This wet sludge is usually disposed of in ponds, but for dam safety reasons the disposal ponds are rarely more than 20 feet (6 meters) deep. In contrast, drier landfill materials can be compacted to a denser product and can be stacked over 100 feet (30 meters) in height. Because of poor structural properties, the calcium sulfate sludge must be dewatered and stabilized before it is deposited in a landfill.

Further, there is increased interest in the use of sodium compounds instead of calcium as the FGD sorbent because of: (1) the higher reactivity of sodium compounds; (2) the lower capital investment; and (3) the greater ease of retrofitting sodium FGD equipment to existing plants. This is particularly true in the case of dry FGD processes involving the use of Nahcolite, a naturally occurring sodium bicarbonate mineral, which is introduced in a dry powdered form into the flue gas of a power plant. The Nahcolite reacts with the SO_(x) in the flue duct and is collected in a baghouse or electrostatic precipitator (ESP). Nahcolite can remove from 70% to well over 90% of the SO_(x) at stoichiometry, depending upon the flue gas temperature. The Nahcolite process has the advantage of producing a dry waste product. In contrast, wet scrubber sludges, being difficult and expensive to dewater, must be disposed of in ponds, or if landfill disposal is desired, must be chemically processed to provide the stability required for the landfill because of their poor structural integrity.

There is some concern over the relative solubility of sodium FGD wastes, which are predominately sodium sulfate. One solution is shown in U.S. Pat. No. 3,962,080, which is directed to the SINTERNA process involving sintering a conglomerate of FGD waste plus fly ash. The resultant sintered pellets have lower solubility than calcium sulfate scrubber sludges; they also have a variety of commercial uses or may be disposed in simple landfills. Another solution to sodium solubility is shown in U.S. Pat. No. 3,984,312 directed to the FERSONA process in which the sodium FGD waste is reacted in solution with ferric ions and sulfuric acid to produce an insoluble basic hydrous or anhydrous sodium hydroxy ferric sulfate or sulfite compound. These compounds are insoluble compared to scrubber sludge calcium sulfate. Both these processes involve additional thermal or chemical processing prior to disposal.

Another approach to the disposal of the sodium FGD waste is the isolation clay landfill. In The Use of Nahcolite Ore and Bag Filters For Sulfur Dioxide Emission Control, ACPA Journal, Vol. 25, No. 12, Dec. 1975, pp 1244-1253, at 1252, there is shown a process for disposal of sodium FGD waste in special landfills. An impermeable base of material is required over which is emplaced a day's production of FGD waste from the power plant. That waste is then covered with a layer of clay on the order of 1 foot thick, forming an isolated clay cell. Each day's production is thus sealed in a clay envelope, generally rhomboidal in cross section. Each succeeding day's production rests in part on the cover and side layers of the preceding day's production. The final cover for the top is a 3 foot thickness of clay-like material, and the sides require a 4 foot layer. While this approach may be environmentally approvable in certain situations, there is concern over the potential for breaching the integrity of the overlying or underlying clay envelope walls, followed by subsequent leaching of the soluble sodium sulfate therefrom by rain water. In addition, there is some fugitive dust problem during the emplacement of the very dry FGD waste. There is also concern over the potential for cracking-open of the envelope(s) if a portion becomes wet and the sodium sulfate expands as it hydrates. This expansion could cause heaving and cracking, thus breaching the integrity of the landfill.

Reginato, et al. in Sodium Carbonate for Reducing Seepage from Ponds. U.S. Water Conservation Laboratory, WCL Report 7, Jan. 1, 1968, 7 pages, recommend treating stock ponds having large quantities of calcium in the water and soil with tech grade granular soda ash to reduce seepage. The soda ash is worked into the bottom and sidewalls of the dry pond to a depth of 4 inches by disking or harrowing. After receiving water, soda ash is added to the water in an amount not exceeding 0.88 lbs/1000 gallons of water (so cattle can still drink the water). Additional sodium is supplied by adding NaCl to the water. This procedure reduces the pond seepage from 5 inches/day to 0.1 inch/day, a 50-fold reduction in seepage.

While produced in relatively small quantities today, the amount of FGD and incinerator waste generated will be increasing rapidly as FGD processes become adopted by industry, municipalities and utilities. Thus, the waste ash problem will be increasing, not only by the changes in regulation requirements and enforcement, but also by the addition of FGD wastes to be disposed in addition to the fly ash, bottom ash and incinerator ash.

Accordingly there is a great need in the industry to provide an improved process for disposing of waste ash alone or in combination with a dry FGD waste, particularly the sodium FGD wastes.

THE INVENTION Objects

It is among the objects of this invention to provide an improved method of preparing waste ash (of all sources) for landfill disposal which results in the stabilization of the waste ash for long term disposal.

It is another object of the invention to provide a method for co-disposal of waste ash and dry sodium FGD sorbent wastes.

It is another object of this invention to provide a method of co-disposal of waste ash by the introduction of a sodium salt compound, preferably a sodium sulfur oxide salt, and a minor portion of smectite clay and/or flocculant.

It is another object of this invention to provide a co-disposal method of insolubilizing waste ash and sodium FGD wastes so that they may be safely disposed in standard landfills by known techniques.

It is another object of this invention to provide a method for disposal of spent nahcolite FGD sorbent by stabilizing the waste in a co-disposal process which also simultaneously disposes of waste ash from the municipal, industrial or utility plant or incinerator which produces the ash.

It is another object of the invention to geomorphologically stabilize waste ash and FGD sodium sorbent wastes, limit their hydraulic permeability to below about 10⁻⁶ cm/sec, and reduce dusting problems.

Still other objects will be evident from the summary, detailed description and the claims which follow.

Summary

The invention comprises a method of preparing waste ash as generically defined above and regardless of source for disposal, which method comprises the steps of providing a waste ash such as fly ash and/or bottom ash, municipal incinerator ash, and/or scrubber sludge containing ash, introducing a sodium salt compound, preferably a sodium sulfur oxide salt, into the waste ash in the range of from about 5 to 85 weight percent on a dry basis to form a waste ash/sodium oxide salt composite. This composite is preferably mixed with a smectite clay additive in an amount in the range of from about 0.1% to about 5%, and/or a flocculant additive in an amount in the range of from about 0.01% to 1.0%, on a dry weight basis, in the presence of sufficient water to produce an additive-enhanced wetted composite, having about 6 to 35% by weight water content, suitable for disposal. The flocculant is a substitute for up to about 3-5 of the percentage points of said water percentage.

While finely divided sodium sulfate and most waste ashes by themselves are highly permeable, surprisingly, the use of the highly water soluble sodium sulfur oxide salts, (solubility on the order of 1-4×10² g/L) renders the composite mix prepared in accord with the invention impermeable, even when used in large quantities (55% or more of the total mix), and even when 18-20% water content is present.

Water movement through soil is called percolation and the measure of it is the permeability. The coefficient of permeability, k, represents the discharge through a unit area at unit hydraulic gradient. Thus, 1 cubic foot per square foot per year at unit gradient is virtually equal to 10⁻⁶ cm/sec. As noted in Design of Small Dams. 2d Ed. 1973, Revised Reprint 1974, U.S. Dept. Interior, Bureau of Reclamation, Water Resources Technical Publication, p. 138, it is customary to describe soils with permeabilities less than foot (10⁻⁶ cm/sec) per year as impervious; those with permeabilities between 1 and 100 ft/year as semi-pervious; and soils with permeabilities greater than 100 ft/year as pervious. "Impermeability" or "impermeable" as used herein is thus the generally accepted standard of below about 10⁻⁶ cm/sec, and preferably below about 10⁻⁷ cm/sec, percolation through the composite, compacted to densities near 100% of maximum density as determined by ASTM D698 in accord with the invention. Even where 10⁻⁶ cm/sec might be considered somewhat borderline, values of 5×10⁻⁶ cm/sec indicates a good mix from the point of view of permeability and may be site-specifically acceptable. Values of 10⁻⁷ cm/sec and below are considered fully impermeable. The composites of this invention show permeabilities on the order of about 5×10⁻⁶ cm/sec or below, as a result of which they are classified as impermeable.

It is preferred to permit the wetted composite to swell for a period of time sufficient that swelling substantially ceases before the additive-enhanced composite is disposed in a compacted landfill. The swell time may range on the order of 1/2 to 8 hours. Typically, the greatest portion of the swelling occurs within the first few hours. The amount of water required depends on the amount of water originally present in the mix components plus additional water needed to achieve the optimum moisture level.

In operation, a surprisingly accurate approximation of the optimum water required for the near maximum density compaction may be achieved by using an amount of water sufficient to produce a composite of dough-like texture. Thus, this visual texture observation may be used in field operation to approximate quite accurately the needed compaction density. Assaying shows that the preferred amount of water is usually in the range from about 15 to 28% by weight, but may range as high as 35%. The water may be added as such or may be present in the FGD waste from wet Ca or Na scrubber sludge.

The composite is considered "set" when a minimum value of penetration resistance of 4.5 Tons/sq.ft. (as measured by pocket penetrometer) is reached. For each particular mix, the lower the moisture content, the shorter the time to set. For moisture contents in excess of optimum, the set times are lengthened (retarded), and for moisture contents lower than optimum, the set times are accelerated. For example, in one test mix as the moisture content increased, the set time was lengthened, from less than 1 hour for 10% moisture to in excess of 15 hours for 20% moisture.

Heating the mix tends to have minimal effect on setting. For example, in one test series using a mix of 59% Ohio Fly Ash, 39.4% sodium sulfate, 1.6% Volclay brand swelling clay (dry weight basis), setting times at ambient temperature for 19.3% and 23% moisture were 9 and 10 minutes respectively. When heated to 100° F. the figures were 4.5 and 14 minutes respectively, and at 150° F. the figures were 9 and 15 minutes respectively.

In most cases, low moisture composites tend to be permeable (in some cases highly permeable), often exhibit lower than optimum density, and often do not compact as well.

We prefer the sodium oxide salt to be a result of using Nahcolite as a dry sodium sorbent in a FGD process. The Nahcolite is provided in a finely divided condition and injected into the flue gas downstream from the super heater tubes of the boiler. The residence time of the Nahcolite is adjusted to provide the desired percentage of SO_(x) removal and is collected in a baghouse or electrostatic precipitator The spent Nahcolite FGD waste is thus a mixture of fly ash and Na₂ SO_(x) wherein x is 3 or 4. There may also be residual amounts of unreacted Nahcolite (sodium bicarbonate), or calcined Nahcolite, (which would be sodium carbonate, Na₂ CO₃). These residuals are present in relatively small percentages as compared to the sodium sulfate/sulfite in the FGD waste. The process of this invention, in disposing of both ash and FGD waste, is a pollutant co-disposal method. However, the process also contemplates using wet sodium FGD wastes, in which case both the Na sulfate/sulfite and water for the process is supplied.

In some plants, the bottom ash may comprise up to about 80% by weight of the entire ash mixture, with the balance being fly ash. In relatively high ash Western coals, the sulfur content is typically low, usually below 0.6%, while the ash content may run as high as 16%. In other coals, the sulfur content may be greater and the fly ash portion of the plant's entire ash production can predominate. Further, it is preferred to employ the bottom ash in relatively small size particles, typically on the order of 60% by weight less than 10 U.S. Standard Series mesh. As in the case of utility bottom ash, the incinerator bottom ash clinkers are generally too coarse and may have to be ground finer. The sulfur content of municipal wastes is generally low, ranging from 0.5-1.5%, and chlorine from 1.0-3.0%.

As set forth below in the Detailed Description, samples of the composites of this invention were subjected to accelerated permeability tests. A 6" layer of each composite mixture was packed to densities approaching 100% of maximum densities as determined by ASTM D698 procedures in a 4" dia column over which was placed 1 foot of water. The column was pressurized to provide a simulated 10 foot water head. The test cells which did not show a breakthrough of water prior to 2 days, would all exhibit a permeability below the 10⁻⁷ "impermeability" standard. That is, in our experience, columns exhibiting significant water passage through the compacted mass followed by breakthrough after about 2 days turned out, upon calculations, to have permeabilities in excess, and in some cases, well in excess of 10⁻⁶ In contrast, in some instances, the composite mixes showed long term no-leak histories (no breakthrough) after periods well in excess of 120 days.

While we do not wish to be bound by theory, we believe that the presence of the sodium sulfate in the composite serves a vital function. The water serves in part to hydrate the anhydrous sodium sulfate and/or sulfite, thus creating an approximate 70-80% volumetric expansion of the affected sulfate and/or sulfite due to recrystallization, and to release sufficient sodium ions to either maintain, or by cation exchange, replace the cations in the exchangeable positions in the smectite clay crystal structure, thus maintaining or producing a high swell potential, thixotropic clay material.

For example, if a calcium-rich montmorillonite is changed to a sodium-rich montmorillonite by cation exchange, its swell potential could increase by up to 50% in some cases. Although the smectite in the mixes exhibits some swelling properties, its most important function is due to its thixotropic characteristic in performing as a lubricant to allow uniform intermixing of the sodium salts and the fly ash components, and as an agent to bind the sodium salts to the fly ash particles.

In the case of Calcium scrubber sludges, the amount of Na sodium sulfur oxide salts may be increased substantially to ensure the expansion/binding and to prevent reconversion of smectite clay to the Ca rich form that can shrink and be nonlubricious in function.

Upon initial mixing, the composites exhibited swelling in relation to the quantity of sodium salts. As sodium salt content increased to the 40-50% range, the swelling increased to 15-20% (i.e. a volume of 115-120% of original mix). Above that sodium salt content level the percent swell tended to decrease. Upon setting (relaxing), the amount of swell determined for the set (relaxed) mixes was lower than the amount of swell determined for the samples immediately after mixing, if the swells determined immediately after mixing exceeded 1.8%; that is, the swells determined for relaxed samples were lower than the swells determined for samples tested immediately after mixing. For mixes of predominantly fly ash and 35-45% sodium salts, the initial swell immediately after mixing was in the 10-20% range. Upon setting (relaxation) for 3-5 hours after mixing, the resultant total (final) swell approached zero. The combination of the volumetric expansion due to hydration of the sulfate and/or sulfite and clay bonding following by setting (relaxation) forms an impermeable composite which effectively retards water migration to a rate below the impermeability threshold.

The process of this invention is relatively simple for field operations. The water requirement may be added at any convenient stage, either directly to the clay, to the ash or to (or be present in) the FGD waste. In some instances, the incinerator ash, bottom ash or FGD waste may have substantial water content sufficient for the composite formation. In other instances, the clay itself may be sufficiently wet. In still other instances, water sufficient to bring a particular mix to the optimum dough-like texture and density may be added, for example, by spraying the water into the composite while it is being mixed. We prefer to premix the required water with the smectite clay to form a slurry, then mix the slurry with the ash/sodium salts mixture, but this slurry formation is not absolutely necessary. It is also preferred to keep the sodium sulfate component dry until the mixing so that the hydrate formation occurs in conjunction with the interlayer transfer of sodium ions into the clay matrix.

The requisite swelling of the composite may occur in various ways: for example, in a special holding pile for later emplacement in a landfill, during transport to the landfill, or after emplacement in the landfill but before being finally compacted and overlain with a clay surface or interlayer. After mixing and swelling, the composite mix is emplaced in a landfill and compacted. The emplacement equipment (front end loaders, graders, dump trucks) running over the surface should suffice for the requisite tamping force. The emplaced composite of this invention is geomorphologically stable so that well in excess of 100-200' high landfills are feasible. The disposed material must be kept below 90° F. to prevent hydrous sulfate breakdown.

Where the landfill requires a bottom liner, an appropriate clay, a natural rubber, or a synthetic plastic liner, such as a Hypalon plastic sheet may be employed. In this regard, the high sodium content provided by the sodium sulfur oxide component of the composite performs a vital function. Where the pond liner is formed from a sodium-base swelling clay, it may be subject to cation exchange in the exchangeable interlayer positions if a cation-rich source is present. The high calcium content of the fly ash could provide sufficient calcium ion to displace the sodium ions in the clay interstructure, thus converting the clay to a variety having less swell potential. This could lead to clay shrinkage and crack formation which could permit breaching of the liner. In the process of this invention, the presence of the sodium oxide salt compound will provide a sufficient excess of sodium ions to prevent the ion exchange and corresponding shrinkage of the liner clay, thus maintaining the integrity of clay bottom liner.

Where a high content of Calcium scrubber sludge is to be disposed of, i.e., in excess of about 50% of the total composite, we prefer to use a rubber or synthetic plastic liner, or an extra thick clay bottom liner with a composite layer devoid or low in Ca sludge just above as an intermediate layer.

It should be understood however, that ordinarily no liner is required for the disposed waste ash and/or sodium FGD wastes in accord with this invention, including Ca scrubber sludges.

X-ray diffraction studies of a typical composite test sample shows that in the first 3 days, the sodium sulfate is in the Thenardite form which is anhydrous sodium sulfate, Na₂ SO₄. By the fourth day, it has been hydrated to the Mirabilite form, the decahydrate Na₂ SO₄.10H₂ O. This is for a typical composite comprising 55% fly ash, 45% sulfate, 1% smectite clay, and 18.5% water. To speed the decahydrate formation, the composite may be seeded with a minor amount of decahydrate crystals, on the order of one pound per one hundred tons, as the seed crystals accelerate the hydrate formation process. In addition to seed crystals, decahydrate formation can be accelerated by temperatures below about 77° F., providing adequate water is available.

The three types of coal burning furnaces produce different ratios of fly ash to bottom ash. For the pulverized coal dry ash furnace, the ratio is on the order of 80 to 20, fly ash to bottom ash. A pulverized coal furnace with a slag tap produces an approximately 50/50 mix, while a cyclone furnace produces approximately 20-30% fly ash and 70-80% bottom ash. While the chemical compositions of the ashes are very similar, the size and form of the particles may vary. The fly ash is generally extremely fine, on the order of 90% less than 200 mesh (74 microns) while the bottom ash is coarser, depending upon the furnace type. Preferably it is ground to approximately 60% passing 10 mesh into the composite for best impermeability results. While unground bottom ash may be used, the fixing of soluble components tends to be less uniform because the resulting composite is less homogenous. The same considerations apply to incinerator ash.

The minimum amount of sodium sulfur oxide compound introducible into the composite needed for the fixing of the ash components is on the order of 5%, with the most preferred minimum being on the order of 9-11%. Generally, the coarser the mix, that is, the larger the average particle size is, the more sodium sulfate is necessary to fix the ash.

The sealant composites of this invention involving the mixtures of combustion waste ashes, sodium compounds and clay impedes the ingress of water into the landfill and retards the solution and removal of soluble species from the disposal site. The invention thus results in limiting, to a practical extent, the loss of soluble species from a disposal site.

As the percentage of sodium sulfate decreases in the range below 45-55% of the total composite mix, the amount of smectite clay should be increased from 0.1% for about 55% sodium sulfate, to 5% for the range of about 5-11% sodium sulfate, as decreasing sodium salt content is accompanied by increasing waste ash content, and more smectite is necessary to maintain the lubrication needed for compacting, thorough blending and for bonding of the particles. Where the sodium sulfate content is greater than about 15-20% in the total composite mix, the grain size of the sodium sulfate is not important. However, when the sodium sulfate content is low, around 5-10%, the sodium sulfate should be fine-grained. The sodium sulfate produced by the use of solution-mined Nahcolite as the sodium sorbent in a dry FGD process is of sufficiently small grain size to provide the appropriate fineness required. When the sodium sulfate content is high, on the order of 75%, the heat of hydration of the sodium sulfate with water is noticeably lower when small amounts, on the order of 0.01 to 1% of flocculant are used.

DETAILED DESCRIPTION OF THE BEST MODE OF THE INVENTION

The following description illustrates the invention by way of example and not by way of limitation of the principles of the invention. This description will clearly enable one skilled in this art to make and use the invention, and describes many embodiments, adaptations, variations and uses of the invention, including what we presently believe is the best mode of carrying out the invention.

I. Materials

All materials were maintained in sealed containers to retard hydration, dehydration and/or contamination.

A. Smectite Clay Sources

A variety of swelling clay sources were used in the test program to simulate a variety of different field locations. These clay sources included soils containing various percentages of Ca, Mg or Na-rich Montmorillonite and one non-soil source, Volclay, a commercially available Na-rich Montmorillonite (bentonite). This product was a greenish-grey powder. Four soils, two from IL (LFS and ILL-C, which were essentially identical) one from KS, and one from CO were used as being potentially locally available sources of smectite clay. The soil samples were pulverized to -1/4 inch and blended. If the soils were too wet to pulverize, they were chopped into approximately -1 inch lumps then blended by hand and grab sampled for individual test use. The soil samples were not oven dried to best simulate field operation moisture content, and to maintain in-place, unaltered clay properties.

The following is a summary of pertinent test data for selected soils:

    ______________________________________                                         KANSAS SOIL (KAN)                                                              ______________________________________                                         Weight % minus two microns=                                                                      18% (Total sample basis)                                     % Mg-rich Montmorillonite=                                                                       16.2% (Total sample basis)                                   Cation Exchange Capacity=                                                                        32.8 meq/100 g. (dry wt basis)                               (CEC)                                                                          Exchangeable Sodium (ES)=                                                                        1.09 meq/100 g. (dry wt basis)                               ______________________________________                                    

    ______________________________________                                         ILLINOIS SOIL (LFS or ILL-C)                                                   ______________________________________                                         % Clay Minerals=  10% (Total Sample Basis)                                     % Ca-rich Montmorillonite=                                                                       2% (Total Sample Basis)                                      Cation Exchange Capacity=                                                                        18.0 meq/100 g. (dry wt basis)                               (CEC)                                                                          Exchangeable Sodium (ES)=                                                                        0.164 meq/100 g. (dry wt basis)                              ______________________________________                                    

    ______________________________________                                         DENVER CLAY SHALE (DCS)                                                        ______________________________________                                         Wt % minus 2 micron=                                                                               24% (Total sample basis)                                   % Ca-rich Montmorillonite=                                                                         22% (Total sample basis)                                   Cation Exchange Capacity=                                                                          26.64 meq/100 g. (dry wt)                                  (CEC)                                                                          Exchangeable Sodium (ES)=                                                                          0.30 meq/100 (dry wt)                                      Maximum Dry Density=                                                                               107.0 lb/cu. ft.                                           Optimum Moisture Content=                                                                          18.5%                                                      Liquid Limit=       42                                                         Plastic Limit=      19                                                         Plastic Index=      23                                                         ______________________________________                                    

Analyses of the major water soluble components in the Denver Clay Shale showed the following:

    ______________________________________                                         DENVER CLAY SHALE SOLUBLES                                                     Major Components  ppm                                                          ______________________________________                                         Ca                76.3                                                         Mg                15.2                                                         Na                63.9                                                         K                 30.8                                                         Si                57.3                                                         SO.sub.4          63.3                                                         Cl                52.0                                                         Total Solubles    376.5                                                        ______________________________________                                    

As received, the Kansas Soil was a dark brown damp soil having 76.1 weight % solids and containing about 16% Mg-rich montmorillonite; it was used as received. The Illinois soils were buff-brown or tan brown soil ranging in size from dust to 6" lumps which were crushed and blended before use. The Denver Clay Shale was a grayish-green soil ranging in size from dust to 6" lumps which were air dried, crushed and blended before use.

Selected moist bulk densities are as follows:

    ______________________________________                                         Moist Bulk Densities                                                                             lb/cu. ft.                                                   Material        % H.sub.2 O                                                                            Uncompacted                                                                               Compacted                                   ______________________________________                                         Denver Clay Shale (DCS)                                                                        18.5    42         127                                         Ill Soil (LFS or ILL-C)                                                                        18.5    50         144                                         Kansas Soil (KAN)                                                                              18.5    125        144                                         Colo FGD Waste (FGD)                                                                           18.5    81         125                                         Ohio Fly Ash No l (OFA-1)                                                                      18.5    44         109                                         Ca Scrubber Sludge                                                                             18.5    54          93                                         Municipal Incinerator Ash                                                                      14.8    66         145                                         ______________________________________                                    

The values were determined by compaction of the sample at the moisture content noted into a stainless steel ring at 500 pounds pressure. At 18.5% moisture content the Incinerator Ash was a slurry and the moisture had to be reduced to 14.8% to run in the test.

B. Ash and FGD Waste

Seven fly ash samples from three different sources were used in the test composites, 3 Ohio Fly Ashes, 2 Kentucky Fly Ashes, and 2 Colorado Fly Ashes. We used one municipal incinerator ash. In addition, we used both dry and wet FGD waste.

The dry FGD waste formed by the injection of dry powdered Nahcolite injected in the flue gas of a Colorado power plant and collected in a baghouse along with fly ash in a dry condition. This was used as an example of a co-disposal waste as it contains both waste ash and sodium sulfate. This FGD waste, also called "spent Nahcolite", was a blended mixture of 12 different FGD pipe samples taken at various times during the Nahcolite process baghouse operational cycle over a 7-day period to insure a representative "average" sample of the waste.

The Ash and FGD waste characterization data is as follows:

                                      TABLE I                                      __________________________________________________________________________     ASH AND FGD WASTE CHARACTERISTICS                                                                Average Particle                                                                        % Organic                                                                            Wt %                                          Sample   Description*                                                                            Size (microns)                                                                          Carbon                                                                               Solids                                        __________________________________________________________________________     CO FGD Waste                                                                            Lt Grey-Brown                                                                           2.3      ND.sup.a                                                                             98.5                                          OH FA-No. 1                                                                             Dark Grey                                                                               5.9      1.28  100.0                                         OH FA-No. 2                                                                             Dark Grey-Black                                                                         6.6      5.15  100.0                                         OH FA-No. 3                                                                             Dark Grey                                                                               3.4      4.22  100.0                                         KY FA Unit 1                                                                            Dark Grey-Black                                                                         9.3      2.25  99.7                                          KY FA-Unit 2                                                                            Dark Buff-Grey                                                                          14.4     2.78  100.0                                         CO FA-No. 1                                                                             Light Grey-Buff                                                                         5.6      1.14  100.0                                         CO FA-No. 2                                                                             Light Grey-Buff                                                                         2.4      ND.sup.a                                                                             100.0                                         Municipal                                                                               Light Grey-Buff                                                                         54.0**   1.08  95.4                                          Incinerator Ash                                                                Ca Scrubber                                                                             Buff     41.5**   .sup. 0.01.sup.b                                                                     72.3                                          Sludge                                                                         __________________________________________________________________________      *All were powders except the scrubber sludge.                                  FA = Fly Ash,                                                                  **Physical Screening Method.                                                   .sup.a ND = Not Determined                                                     .sup.b Total Carbon 3.59%                                                

Overall the data show wide variations in average particle size between different fly ash samples and between fly ash samples having the same origin. Regarding the organic carbon data, wide variation was noted between the Ohio Fly Ash samples (1.28-5.15%), but little variation was present between the two Kentucky Fly Ash samples (2.25-2.78%). No definite trending could be noted between the average particle size and the organic carbon content for the listed fly ash samples. All of the ash materials were individually blended before use. The average particle size data for the incinerator ash and scrubber sludge was obtained by use of a physical screening method. All other materials were evaluated using an air comparison pycnometer in conjunction with a Fisher sub-sieve analyzer. The correlation between the two methods was not determined.

The measured densities of the three Ohio Fly Ash samples, as received, ranged from 67-83 lb/cu.ft uncompacted and 74-92 lb/cu.ft. compacted. The uncompacted and compacted bulk densities of the two Kentucky Fly Ash materials were 62-66 lb/cu.ft. and 72-73 lb/cu.ft., respectively. The two Colorado Fly Ash samples were 45-52 lb/cu.ft. uncompacted and 54-60 lbs/cu.ft. compacted.

Following are data regarding the water soluble components in selected waste ash and FGD waste samples.

                  TABLE II                                                         ______________________________________                                         WATER SOLUBLE COMPONENTS-FLY ASH                                               AND FGD WASTE                                                                                                   Total                                                    Major Components                                                                             % Of    Water (ppm)                                   Sample     (ppm)         Total   Solubles (ppm)                                ______________________________________                                         CO FGD Waste                                                                              Na-91,649     73.1    125,465                                                  SO.sub.4 -31,687                                                                             25.32                                                            Cl-1,500      1.2                                                              Nitrite-268   0.2                                                   OH FA-No. 1                                                                               SO.sub.4 -3,357                                                                              67.8    4,948                                                    Ca-1,221      24.7                                                             B-89.2        1.8                                                   OH FA-No. 2                                                                               SO.sub.4 -6946                                                                               78.5    8,843                                                    Ca-1,246      14.1                                                             Na-323        3.7                                                              K-233         2.6                                                   OH FA-No. 3                                                                               SO.sub.4 -7,936                                                                              98.3    8,073                                         KY FA-Unit 1                                                                              Ca-12,016     50.9    23,591                                                   Na-5,047      21.4                                                             K-3,148       13.3                                                             SO.sub.4 -2,374                                                                              10.1                                                             Al-523        2.2                                                              Si-329        1.4                                                   KY FA-Unit 2                                                                              Na-4,786      50.2    9,531                                                    Ca-2,510      26.3                                                             SO.sub.4 -98910.4                                                              K-922         9.7                                                   CO FA-No. 1                                                                               Ca-9,458      45.6    20,762                                                   Na-6,443      31.0                                                             Al-2,305      11.1                                                             SO.sub.4 -2,096                                                                              10.1                                                             K-260         1.2                                                              B-90.         50.4                                                  ______________________________________                                    

These data show that the Colorado FGD Waste had the highest water soluble content (125,465 ppm). This is expected as the FGD process involved employs a sodium sorbent resulting in Na₂ SO₄ as the predominant waste in the fly ash/spent sorbent mix. This was followed by the Kentucky Fly Ash-Unit 1, then the CO Fly Ash No. 1. The No. 2 and No. 3 Ohio Fly Ashes had similar water soluble contents while the No. 1 Ohio Fly Ash had the lowest water solubles content. The water soluble contents of the Kentucky Fly Ash Numbers 1 and 2 varied widely.

C. Sodium Salts

The FGD waste containing sodium salts (predominately Na₂ SO₄, but also containing some Na₂ SO₃, NaHCO₃ and Na₂ CO₃) was described above. Other sodium salts which were used in the composite formulations are Na₂ SO₃, NaHCO₃, Na₂ SO₄, and Na sulfite/sulfate/carbonate mixtures (one high in Sulfate, two high in Sulfite). All samples were white powders and were used as received after blending. The Na sulfate/sulfite/carbonate mixture was a blended sample produced by reaction of SO₂ with a fluid bed of sodium bicarbonate (solution-mined Nahcolite from Industrial Resources, Inc., Lakewood, Colo.), and it assayed approximately 50.1% Na and 20.72% Na₂ SO₃. Two samples high in sodium sulfite were prepared in the same way and had essentially similar assays: pH 10.10-10.65; Na₂ SO₃ 32.7-41.0%, with the balance split between Na₂ SO₄ (52.7-48.5%) and Na₂ CO₃ (14.6-10.5%).

The sodium sulfate was a commercial product of -325 mesh used as Na₂ SO₄ without analysis.

D. Flocculants

Flocculants were used in place of, or in addition to, the clay sources in the composite mixtures and were used as received. These materials were as follows:

    ______________________________________                                         Flocculant   Description                                                       ______________________________________                                         Percol 351   White Powder                                                                               Nonionic dry powder,                                                           100% active solids.                                   Calgon Catfloc "C"                                                                          Reddish Brown                                                                              Cationic, 2000-4000 cps                               (CAT-C)      Viscous Liquid                                                                             viscosity at 25° C., mole-                                              cular weight 250-                                                              500,000.                                              Calgon Catfloc "LV"                                                                         Yellow Viscous                                                                             Cationic, 35 cps                                                               viscosity at 25° C.,                           (CAT-LV)     Liquid      molecular weight                                                               250-500,000.                                          Chem-Link CP-40                                                                             Brown Liquid                                                                               Inorganic solution of                                 (CHEM)                   50% Ferric sulfate,                                                            50% solids.                                           Chem-Link 5P-60                                                                             Clear Viscous                                                                              Cationic at <8.0 pH,                                  (CHEM)       Liquid      2000-3500 cps viscosity                                                        at 25° C., molecular                                                    weight 20,000,000,                                                             1.6% active solids.                                   ______________________________________                                    

The Percol 351 is available from Allied Colloids, and the Chem-Link flocculants are available from Chem-Link, Division, Arco Chemical, Newtown Square, Pa. The Chem-Link flocculants were mixed 2:1 CP-40:5P60 prior to use. The Calgon Catfloc C and LV flocculants are available from Calgon Corporation. The Catfloc C contained 40% solids, while the LV contained 20% solids. In all cases, flocculants were used in the composite mixtures in amounts less than 0.1 weight % (dry weight basis); they were mixed with the water required to achieve the desired moisture content. In addition to the above flocculants, Superfloc 127 or SF-363 from American Cyanamid, Wayne, N.J. can be used.

II. Preparation of Composite Mixes

All mixes forming the composites of this invention were prepared at room temperature (around 70° F.) as follows: First, moisture contents were determined (where applicable). Then, blended portions of the materials used were obtained and size reduced to -10 mesh where necessary. In mixes where it was required that certain components be premixed with water, the components were mixed with a minimum amount of water to form a slurry in either a Waring-type or a Hobart-type blender until thorough blending was achieved. These premixed slurries were then blended into the other dry components using a laboratory scale mortar mixer unit. Mixing typically took 30 seconds in the Waring-type blender, and 1-3 minutes in the Hobart-type blender.

Water was then added in small increments to the materials until a consistency was reached that allowed the mass to agglomerate in the mixer into a single coherent dough-like ball that did not stick to the sides of the mixer container. This was the composite of the invention.

This composite mixture was removed from the mixer container and formed into a mass approximately 8" in diameter by 11/2" thick. This mass was separated into 4 approximately equal portions; each portion representing one lift to be compacted into the test columns.

When premixing was not required, the same procedure was followed less the mixing in the Waring or Hobart blender. In all mixing procedures, deionized water was used.

Prior to any mixing, the weight percents of the components used, including an estimated amount of water, were calculated (based upon dry weight basis amounts of materials and water). After mixing, the component weight percents were recalculated based upon the actual amount of water used. The composites tested for impermeability characteristics are set forth below.

IIA. Moisture Addition Level

To determine moisture addition levels required, moisture addition studies were performed on the Colorado FGD Waste/Ash and the Ohio Fly Ash No. 1 samples. The samples were mixed with various amounts of water in a Hobart-type blender and observations made. The tests were continued until a mass was formed that had end points of (1) dry enough to handle without sticking to the mixing vessel, and (2) plastic enough to pack properly into the test columns. In Table III below, Tests 1-6 are on the CO FGD Waste/Ash sample, and Tests 7-12 are on the Ohio Fly Ash #2.

                  TABLE III                                                        ______________________________________                                         MOISTURE ADDITION LEVEL                                                        Test   Wt. %                                                                   No.    Water     Observations (Final Mix)                                      ______________________________________                                         1      50.8      Wet and fluid                                                 2      34.3      Wet and fluid                                                 3      26.1      Wet and fluid                                                 4      21.1      Damp mass tending to ball                                     5      19.4      Definite dough-like, but surface wet.                          6*    17.9      Tough, dough-like mass; very cohesive;                                         surface appearance moist.                                     7       7.6      Dry, but forming damp balls up to 1/2"                        8      15.3      Mix is damp; forming damp balls up to 1/2"                    9      19.9      Like 15.3 wt %, but a little damper.                          10     23.0      Starting to get dough-like.                                   11     23.6      Mix is damp, but not thixotropic, starting                                     to stick to bowl                                              12     24.2      Looks thixotropic when smoothed with a                                         spatula or vibrated.                                          ______________________________________                                          *When Test 6 conditions were reached, the mass tended not to stick to the      mixing bowl or paddle.                                                   

These tests showed that the proper dough-like state was reached at 17.9% moisture in the Colorado FGD Waste/Ash sample, and at between 23.0 and 23.6% moisture in the Ohio Fly Ash No. 2 sample.

Subsequent mixes used for the column studies to determine the relative impermeability of the composites of this invention were made in the laboratory mortar mixer employing the visual end points described above as the operational guide.

IIB. Hold Time

Depending on the landfill design configuration, in some cases swelling of the emplaced composite could rupture the landfill cover, bottom or side walls. Thus, where this could be a problem, it is necessary to permit the composite mixes to swell before covering, or possibly, before emplacing. Accordingly, several composite mixes of the invention were subjected to one-dimensional swell consolidometer studies to determine the percentage of such swelling which occurs after a given holding period. These studies show that the holding period before covering ranges from about 0.5 to about 8 hours. Thus, we prefer to let the composite swell, either unconfined or confined (compacted), before covering for such a period in cases where landfill integrity could be compromised by a swelling-caused breach. The holding can occur in open set-aside piles, during transportation to the fill, or at the fill site before, during or after compaction, but before covering with barrier layer(s), e.g. of clay.

The composite mixes to be tested were placed into stainless steel rings 1-15/16 inch I.D. by 11/4 inch high. The mixes were compacted to produce samples having effective heights of one inch. Porous media were placed above and below the samples, and the rings were then placed into a plastic cup that could be filled with water if required. The test rings containing the samples were then placed into the consolidometer test unit, and the swell or shrink in the sample was measured using a dial indicator. The movement experienced was compared to the initial dial indicator reading to determine shrink or swell. Additional weight could be added to the unit to exert a downward force on the specimen during the testing.

In each test series, six identical samples were prepared. The first was placed immediately after mixing in the consolidometer test unit. The dial was read and the sample was left in the apparatus for up to five days to allow attainment of maximum swell and equilibration. The final reading was then taken and the % swell calculated.

The second sample was let hold (i.e., permitted to swell, free of constraint) for a 1 hour period before being placed in the consolidometer and the procedure repeated. The third was let set 2 hours, and so on, with the sixth in holding for 5 hours before placement in the consolidometer.

Series I. In this series, the swell was determined for samples containing 52.2 dry wt % Ohio Fly Ash No. 1, 42.8 dry wt sodium sulfate/sulfite/carbonate mix (the high Sodium Sulfite mix described above), 5.0 dry wt % Kansas Soil, and 18.0% water. In this series a downward force of 1.8 lb/sq. in. was applied to the samples. The samples were sealed in plastic membranes during the test. The results of those studies are:

    ______________________________________                                         Series I                                                                       Holding Time In % Additional Swell                                             Hours After Mixing                                                                             After 5 Days                                                   ______________________________________                                         0               10.3                                                           1               6.0                                                            2               3.8                                                            3               1.9                                                            4               0.5                                                            5               -0.1                                                           ______________________________________                                    

These data show that the sample that was tested immediately after mixing showed over 10% swell, and that after holding (setting) for five hours after mixing, the measured swell was less than 0% (i.e., some slight shrinkage occurred). This indicates that some hold time should be allowed after mixing and before covering if no swell is desired in a compacted body.

Series II. In this series, swell was determined for a composite mix under a greater loading than was used in Series I. The composite mix used in this series was 52.2% dry wt % Ohio Fly Ash No. 3, 42.8% dry wt % sodium sulfate/sulfite/carbonate mix described above in Series I, 5.0% dry wt % Kansas Soil, and 21.7 % water. In these tests 4.0 lb/sq.in. downward force was applied to the specimens. As in Series I the samples were sealed in plastic membranes during the test. The results of these studies are:

    ______________________________________                                         Series II                                                                      Holding Time in % Additional Swell                                             Hours After Mixing                                                                             After 5 Days                                                   ______________________________________                                         0               19.5                                                           1               14.6                                                           2               2.9                                                            3               0.2                                                            4               1.4                                                            5               2.3                                                            ______________________________________                                    

These data show that letting the mix set for three hours after mixing reduced the additional swell from 19.5% to 0.2%, but that slight swell was again noted in mixes that were allowed to hold (set) for four and five hours prior to test.

Series III. Samples were prepared from composite mix containing various amounts of Ohio Fly Ash No. 2 and Ground Sodium Sulfate. One half of each of these mixes was allowed to hold for five hours after mixing prior to testing, and one half of each of the mixes was testing immediately after mixing (zero hold time). These samples were tested using 1.8 lb/sq.in. downward force. All samples were sealed in plastic membranes during testing. The results of those tests, after 5 days of testing when swells were equilibrated, are:

    ______________________________________                                         Series III                                                                                                  % Additional                                                                   Swell (Holding                                    Dry Wt %                     Time Prior                                        Ohio                         to Testing)                                       Fly Ash                                                                               Sodium Sulfate                                                                             Volclay  % Water                                                                               0 Hr  5 Hr                                  ______________________________________                                         96.7   2.0         1.3      23.8   -0.1  -0.1                                  93.6   5.1         1.3      22.0    0.0  -0.1                                  88.8   9.9         1.3      20.4    3.5   3.0                                  85.0   13.9        1.1      21.5    7.7   3.0                                  78.7   20.0        1.3      21.5    15.6  0.9                                  ______________________________________                                    

The data shows that: (1) The percent swells noted in samples tested immediately after mixing tended to increase with increasing sodium sulfate content (decreasing fly ash content); and, (2) All swells noted in samples held for five hours after mixing were lower than the swells noted in samples tested immediately after mixing.

Series IV. Tests were performed using only the Colorado FGD Waste/Ash mixture with various amounts and types of water dedition in order to simulate prior art landfill breach problems. The results of those studies are:

The Colorado FGD Waste/Ash material containing 17.9% moisture was hand compacted into a test ring. The loading was 0.5 lb/sq.in. With no water in the cell the sample showed no movement for five days. When water was added to the cell (representing a breach in prior art landfill), 14.3% swell was noted. The sample was not sealed in an impervious membrane.

B. The Colorado FGD Waste/Ash material was dry packed into a test ring using 1,000 lbs. pressure (resultant sample 88 lb/cu.ft.). The sample was tested using a loading of 0.5 lb/sq.in. The sample was placed in an impervious membrane during the test. After two days of testing in air the sample had shrunk -0.5%. At that point water was injected into the sample with a needle to produce a theoretical 18.0% moisture content. After this injection, the sample showed an additional 2.9% swell in the following 11 days.

C. The Colorado FGD Waste/Ash material was loose filled into a test ring (resultant sample=35 lb/cu.ft.). The sample was tested using a loading of 1.0 lb/sq.in. The sample was not sealed in an impervious membrane. After two days of testing in air the sample showed 0.4% shrinkage. At that point water was injected into the sample to produce a theoretical moisture content of 18.0%. After this injection, the sample showed an additional 1.1% swell in the following 11 days.

This series shows that the 1.1 to 14.3% swelling after water intrusion represents a design problem for unstabilized dry FGD waste landfills.

Series V. In this series, Ohio Fly Ash No. 1 and the sodium salt source (described above in Series I) were blended with various additives to form a composite of the invention. The moisture contents of all mixes were held at 18.0%. The loading on the samples was 1.8 lb/sq.in. All samples were tested in air inside impervious membranes. There was no hold time and the maximum swell developed within a few hours to 3 days. The results are:

    ______________________________________                                         Series V                                                                       Wt % (Dry Basis)           Maximum                                             Ohio Fly Ash                                                                            Sodium Salts Additive     % Swell                                     ______________________________________                                          55.0*    45.0*       None         19.6                                        55.0     45.0         <0.1 Catfloc-C                                                                              9.0                                         55.0     45.0         <0.1 Catfloc-C                                                                              10.1                                        53.9     44.1          2.0 Volclay 10.6                                        53.9     44.1          2.0 Volclay 8.8                                         55.0     45.0         <0.1 Percol 351                                                                             11.9                                        52.2     42.8          5.0 Kansas Soil                                                                            19.3                                        ______________________________________                                          *This represents a simulated FGD waste mixtures of fly ash and sodium          sulfate/sulfite/carbonate.                                               

The swell of the composite containing Percol 351 flocculant showed a swell of 11.9% which is comparable to the swells noted for the samples containing Catfloc-C flocculant and the Volclay.

Series VI. In this series, the Colorado FGD Waste/Ash mixture was mixed with various additives at various moisture contents to form composites of the invention. Swell was determined using a loading of 1.8 lb/sq.in. All samples were tested in air inside of impervious membranes. There was no hold time. The maximum swell developed within 1-3 days. The results are:

    ______________________________________                                         Series VI                                                                      Wt % (Dry Basis)                                                               Colo. FGD                          Maximum                                     Waste/Ash Mixture                                                                           Additive     % Water  % Swell                                     ______________________________________                                         95.0          5.0 Volclay 15.7     3.5                                         95.0          5.0 Volclay 18.0     2.1                                         86.3         <0.1 Catfloc-C                                                                              13.7     2.0                                         98.0          2.0 Volclay 15.3     2.5                                         ______________________________________                                    

The data shows: (1) Regarding the two mixes containing 5.0 Wt % Volclay, the one containing 15.7% water swelled 3.5% while the one containing 18.0% water swelled 2.1%. This may indicate that optimum water acts as a lubricant to promote better packing. (2) The sample containing 2.0 wt % Volclay and 15.3% moisture swelled 2.5%. This is 1.0% less swell than the sample containing 5.0% Volclay at a similar moisture content. This may indicate that lower additive amounts are the optimum amount of particle lubricant and thus can reduce swelling, even in the absence of a hold period. (3) The sample containing Catfloc-C swelled 2.0%. This swell is considerably lower than the 9-10% swell noted from samples containing 55.0% Ohio Fly Ash and the high Sodium Sulfite sodium salt source (described above in Series I).

III. Accelerated Percolation/Relative Impermeabilitv Testing

The test columns were 4 inch diameter PVC plastic pipe, approximately 2 feet long fitted with a perforated disc at the bottom end. A piece of stainless steel screen (approximately 40 mesh) and a layer of coarse fiberglass were placed on top of the perforated disc. Two inches of sand were then placed on top of the fiberglass layer, and the composite mixes to be tested were compacted into the columns in four equal lifts. After the mixes were compacted to theoretical density (except where noted), 1 foot of deionized water was added above the composite in the columns and nitrogen or air pressure was used to simulate a ten (10) foot water head.

Daily measurements were made of any leakage. The columns were usually removed from test when essentially all of the original amount of water had percolated through under the 10 foot head pressure. In some cases the columns never leaked before they were taken out of service or the test terminated, even after many days (from 10 to over 150 days). For these columns it is not possible to calculate the permeability constant in cm/sec. But they are all clearly impervious with k values of well below 10⁷, and could even be 10¹¹ or less. Similarly, some of the comparative columns began leaking immediately. Some leaked so fast that it was not possible to measure the rates. Thus, while the permeability is not precisely known, it is clear that they are pervious or highly pervious with k values well above 10⁻⁶, and most likely in the 10² -10⁻² range.

That is, test columns can show some amount of water passage therethrough under the 10' pressure head even from the beginning, yet depending on the rate, can be greater or lesser than the 10⁻⁷ impermeability standard. Breakthrough, by its own term, means a flood of water through the packed composite of the column, as distinct from channelling around the sides of the compacted mass, between it and the inner wall of the column. Thus, where there was some slight passage of water through the compacted mass, the amount (in ml), collected permitted calculation of the exact values, e.g., the columns shown in the following Tables P-V, PVI, P-VII, P-VIII, Columns 75 and 80R in P-IX, Columns 53 and 65 in Table P-X, and columns 107 and 143 in Table P-XII below. In columns where there was no breakthrough for long periods, there are no standards regarding the length of time our permeability tests should be run to confirm permeability or impermeability. However, our experience shows that for columns configured as described herein (compacted height of 6" or less), those test columns requiring more than 2 days to saturate and leak generally result in calculated coefficients of permeability, k, of less than 10⁻⁷ cm/sec. Indeed, in such examples, although the precise permeability value is unknown, we believe that the actual permeability of such long term samples will be several orders of magnitude less than 10⁻⁷ cm/sec. Thus, we identify them simply as <10⁻⁷.

The Tables P-I through P-XII below (P, for Permeability studies) summarize the composition of the composite mixes within the scope of the invention and their corresponding permeabilities, in terms of the constant K of hydraulic conductivity and permeability in cm/sec. Some of the tables show comparative tests of compositions or components, e.g. ash alone, outside the scope of the invention. Any values of 10⁻⁶ or below are considered impermeable and any above that are pervious (permeable). The abbreviations for the ash types and additives are the same as above. All flocculants were added in amounts of less than 0.1 wt % dry basis.

Table P-I below shows as a comparative test a series of test columns of waste ash, used as received, and tamped to 6" depth in the columns prior to the addition of the water. Due to packing difficulties (the fly ash and incinerator ash materials were fluffy, dry powders) optimum dry density was probably not attained even though the columns were tamped. No sodium salt(s), clay or flocculants were used; no particular attention was paid to insure an optimum water content was present in the as-received materials. The water head broke through in minutes, showing that the permeability was certainly well above 10⁻⁶, and probably in the 10⁻¹ to 10⁰ range. Clearly the waste ash (raw fly ash incinerator ash, dry FGD waste or scrubber sludge) can be highly permeable and is unsuited for untreated land filling.

                  TABLE P-I                                                        ______________________________________                                         Comparative Test of Untreated Components                                       Col  Ash or   Addi-            Time to K-Perm                                  No.  Waste**  tives   Water %  Breakthru                                                                              cm/sec                                  ______________________________________                                         176  CO#2     None    As received                                                                             37 min. >10-6*                                  177  KY#2     None    As received                                                                             15 min. >10-6*                                  178  OFA#3    None    As received                                                                             38 min. >10-6*                                  179  CO-Dry   None    As received                                                                             63 min. >10-6*                                       FGD                                                                            Waste                                                                     241  OFA      None    As received                                                                             Next day                                                                               >10.sup.-6                              242  OFA      None    As received                                                                             Same day                                                                               >10.sup.-6                              276  Scrb     None    27.7%*** Next day                                                                               >10.sup.-6                                   Sldg                                                                      279  Scrb     None    27.7%*** Same day                                                                               >10.sup.-6                                   Sldg                                                                      281  Scrb     None    27.7%*** Next day                                                                               >10.sup.-6                                   Sldg                                                                      282  I.A.     None    17.5%    Next day                                                                               >10.sup.-6                              304  50% I.A. None    22.0%    See Note                                                                               2.1 × 10.sup.-5                        50%                       Below                                                Scrb                                                                           Sldg                                                                      ______________________________________                                          *Precise measurements were not possible due to the rapidity of                 breakthrough. Probably in the 10.sup.-1 to 10.sup.0 range.                     **Scrb Sldg = Scrubber Sludge; I.A. = Incinerator Ash                          ***As received 35.2%                                                           Notes:                                                                         Column 276  No sand in tube; no bentonite on sides.                            Column 279  Sand in tube; no bentonite on sides                                Column 281, 282, 304  bentonite on sides                                       Column 304  Leaked continuously and blew out before end of 4th day.      

Table P-II below shows as a comparative test a series of test columns of waste ash mixed with flocculant, clay, soil, or calcium scrubber sludge (column 32). The data showed that even with water in the optimum range, but without the use of sodium salts, the requisite impermeability was not achieved. In short, the absence of the sodium salts results in mixes that are permeable.

                                      TABLE P-II                                   __________________________________________________________________________     Comparative Test of Mixes Lacking Sodium Salts                                    Waste                     Time                                              Col                                                                               Ash      Additives    Water                                                                              in       K-Perm                                   No.                                                                               %        %            %   Days     cm/sec                                   __________________________________________________________________________     20 100.0                                                                             OFA-1 PERCOL       18.5                                                                               0        >10.sup.-6 *                             19 98.8                                                                              "     1.2                                                                               VOL       18.5                                                                               0        >10.sup.-6 *                             21 98.8                                                                              "     1.2                                                                               VOL + PERCOL                                                                             18.5                                                                               0        >10.sup.-6 *                             32 90.6                                                                              "     9.4                                                                               SCRB SLDG 20.5                                                                               0        >10.sup.-6 *                             28 95.0                                                                              "     5.0                                                                               ILL-C     18.5                                                                               0        >10.sup.-6 *                             29 89.9                                                                              "     10.1                                                                              ILL-C     18.5                                                                               0        >10.sup.-6 *                             289                                                                               98.4                                                                              I.A.  1.6                                                                               VOL       16.4                                                                               See Notes Below                                   290                                                                               98.4                                                                              Scrb  1.6                                                                               VOL       34.8                                                                               0        >10.sup.-6 *                                   Sldg                                                                     __________________________________________________________________________      *Precise measurements were not possible due to the rapidity of                 breakthrough.                                                                  Notes:                                                                         Column 289, 290 sand in tubes; Bentonite on sides; Col 289 showed              continuous leakage; it was pressurized at 18:16 hrs on day 0; the next da      (day 1) at 10:26 hrs it leaked 1l8 ml; 2nd day at 9:21 hrs, 758 ml; 3rd        day at 10:30 hrs, 1020 ml which = failure.                               

Table P-III below is a series of composites in accord with the invention which show stabilization of composites having from 1.9% to 87.4% of the CO FGD waste. The mixes were packed into the columns immediately after mixing. The CO FGD waste was a mix of fly ash and spent Nahcolite, containing 12.5% Na₂ SO_(x) salts, where x is 3 or 4, and some minor amounts of Na₂ CO₃ and possibly some unreacted NaHCO₃. The value under the FGD % column is the total FGD waste in the mix. The value under the SS (sodium salt) % column is the amount of sodium sulfate/sulfite/carbonate in the composite. The "K-Perm" values listed as "10⁻⁷ " are all well below 10⁻⁷ as there was either no leakage before the columns were taken down or the columns were still in service after 153 days with no breakthrough. In the tests where slight water passage was noted and collected, the precise permeability values could be calculated and are reported (cols 17,18,11,16,74,9,10 and 8).

                                      TABLE P-III                                  __________________________________________________________________________     FGD Composite Impermeabilities                                                 Col FGD SS               Water                                                                              Days K-Perm                                       No. %   %  Additive %    %   No Leak                                                                             cm/sec                                       __________________________________________________________________________      1A 1.9 0.3                                                                               97.8                                                                              DCS        18.5                                                                               15   <10.sup.-7                                    1B 1.9 0.3                                                                               97.8                                                                              DCS        18.5                                                                               15   <10.sup.-7                                    3A 1.9 0.3                                                                               97.8                                                                              DCS + OIL  18.5                                                                               15   <10.sup.-7                                    3B 1.9 0.3                                                                               97.8                                                                              DCS + OIL  18.5                                                                               15   <10.sup.-7                                    4A 1.9 0.3                                                                               97.8                                                                              DCS +      18.5                                                                               15   <10.sup.-7                                                 PERCOL 15                                                         4B 1.9 0.3                                                                               97.8                                                                              DCS +      18.5                                                                               15   <10.sup.-7                                                 PERCOL                                                            5A 1.9 0.3                                                                               97.8                                                                              DCS +      18.5                                                                               15   <10.sup.-7                                                 OIL + PERCOL                                                      5B 1.9 0.3                                                                               97.8                                                                              DCS +      18.5                                                                               15   <10.sup.-7                                                 OIL + PERCOL                                                      2B-2                                                                              43.7                                                                               6.3                                                                               50.0                                                                              DCS        14.4                                                                               20   <10.sup.-7                                    6  43.7                                                                               6.3                                                                               50.0                                                                              DCS        16.5                                                                               15   <10.sup.-7                                   17  78.6                                                                               11.3                                                                              10.1                                                                              DCS        18.5                                                                               25   2.0 × 10.sup.-8                        18  83.1                                                                               11.9                                                                              5.0                                                                               DCS        18.5                                                                                1   2.9 × 10.sup.-7                        49  83.1                                                                               11.9                                                                              5.0                                                                               DCS        18.5                                                                               153  <10.sup.-7                                    2A 85.5                                                                               12.3                                                                              2.2                                                                               DCS        18.5                                                                               15   <10.sup.-7                                   11  85.5                                                                               12.3                                                                              2.2                                                                               DCS        18.5                                                                               12   5.4 × 10.sup.-8                        16  85.5                                                                               12.3                                                                              2.1                                                                               DCS        20.0                                                                                9   2.8 × 10.sup.-8                        48  85.5                                                                               12.3                                                                              2.2                                                                               DCS + CAT-C                                                                               18.5                                                                               153  <10.sup.-7                                   74  85.5                                                                               12.3                                                                              1.7                                                                               LFS + 0.5 VOL                                                                             18.5                                                                                1   1.2 × 10.sup.-6                        63  83.1                                                                               11.9                                                                              4.5                                                                               LFS + 0.5 VOL                                                                             18.5                                                                               90   <10.sup.-7                                    9  86.4                                                                               12.4                                                                              1.2                                                                               VOL        18.5                                                                               77   3.6 × 10.sup.-9                        10  86.4                                                                               12.4                                                                              1.2                                                                               VOL        18.5                                                                               117  3.9 × 10.sup.-9                        60  85.7                                                                               12.3                                                                              2.2                                                                               VOL        19.4                                                                               131  <10.sup.-7                                   61  87.4                                                                               12.6  CHEM       18.3                                                                               126  <10.sup.-7                                   47  87.4                                                                               12.6  CAT-C      19.4                                                                               153  <10.sup.-7                                    8  87.4                                                                               12.6  PERCOL     18.5                                                                               98   2.4 × 10.sup.-9                        __________________________________________________________________________

Table P-IV below is a comparative test series that demonstrates optimum water criticality for composite impermeability. The FGD was CO FGD waste described above for Table P-III.

                  TABLE P-IV                                                       ______________________________________                                         Water Criticality                                                                    Water                  Wa-  Time in                                      Col   or      SS      Additive                                                                              ter  Days of                                                                               K-Perm                                No.   Ash %   %       %      %    No Leak                                                                               cm/sec                                ______________________________________                                          2B-1 85.5*   12.3    2.2 DCS                                                                               10.2 0      >10.sup.-6                             13   85.5*   12.3    2.2 DCS                                                                               10.2 0      >10.sup.-6                             14   85.5*   12.3    2.2 DCS                                                                               14.0 0      >10.sup.-6                             7    87.4*   12.6    NONE   18.5 11     5.8 × 10.sup.-7                 167   45.0    55.0a   NONE   17.2 13     <10.sup.-7                            168   30.1    69.9a   NONE   16.6 13     <10.sup.-7                             15   87.4*   12.6    NONE   10.0 0      >10.sup.-6                             68   100.0   NONE    NONE   22.8 1      3.5 × 10.sup.-6                 ______________________________________                                          *CO FGD Waste                                                                  a = ground sodium sulfate                                                

Columns 2B-1, 13 and 14 should be compared to columns 2A, 11 and 16 in Table P-III. The 10.2% and 14% values of water in columns in 2B-1, 13 and 14 were too low, and there was quick breakthrough. But when the water content is in the proper range for this waste or ash to be disposed, e.g. around 18.5-20%, the permeability suddenly drops to the 10⁻⁶ range and below as seen in Columns 2A, 11 and 16. Columns 7 and 15 in Table P-IV also show this water criticality aspect of the invention. In comparing column 7 to columns 2A, 16, and 48, there is at least a 10-fold increase in impermeability by use of the additives with the sodium salts as compared to no additives. Column 7 shows that sodium salts alone added to fly ash at proper water percentages can produce a composite in the impermeable range, but in comparing 7 to 2A, 11, 16 and 48 we see progressive lowering of the permeability (greater impermeability) by use of the appropriate additives. Columns 7, 167 and 168 show that with the critical water percentage, ash plus sodium salts can be rendered impermeable even without additives of clay or flocculant.

Column 68 is typical of a fly ash of the self-hardening bituminous coal type having low mean mass diameter, high solubles, and high in calcium hydroxide. Such ashes may exhibit properties of a pozzolan, i.e. a siliceous or siliceous and aluminous material which in itself possesses little cementitious value, but will, in finely divided form, and in the presence of moisture, chemically react with Ca(OH)₂ at ordinary temperatures to form compounds possessing cementitious properties. Such ashes may be marginally impermeable, are typically not easily compacted if set, and may be site-specifically approvable for disposal without treatment by the process of this invention. However, even pozzolanic ashes can be used in the composites of this invention to improve their impermeability values.

The following Tables P-V through P-XII list data on columns containing increasing amounts of sodium salts (SS), from 2% to 75%, and decreasing amounts of Fly Ash and other additives (clay, clay-containing soil, or flocculant; called "FA+A" in the tables below), from 98% to 25%. The 2% SS/98% FA+A (Table P-I) columns are examples of using the sodium salts to stabilize/impermeabilize waste ashes, and the 25% FA+A/75% SS (Table P-XII) columns are examples of using FA+A to stabilize/impermeabilize sodium sorbent FGD wastes. The data on the 25% FA+A and 75% SS (Table P-XII) indicates that at very high SS percentages, the formulation is a bit more sensitive, and we may be approaching the limit of SS disposal. For example, columns 90, 102 and 148 (Table P-XII) indicate that 5% Kansas soil (of which only 16.2% is Mg-rich montmorillonite) is too little additive, 10% would be marginal (by extrapolation), and 15-20% is clearly adequate Other soils may be required in smaller or larger percentages depending on the smectite clay content. The Column 148 was also too wet.

Column 147 in Table P-XII illustrates that the flocculants tend to function as water enhancers. Thus, in adding flocculant the water content should be reduced, if near the upper limit of water. Conversely, less water may be used to reach theoretical density and compaction. The proportion is approximately 10-30x; that is, for each 0.1% flocculant the water content can be reduced 1.0-3.0%. Thus, column 147 as compared to column 91 (also in Table P-XII) indicates the water/flocculant content of Column 147 is too high, being effectively 24-26%, while in column 91 it is only 20.5-22.5%. Similarly columns 151 and 120 in Table P-V tend to show that high clay content may act similarly with water, as does flocculant, at least for low sodium salt concentrations. In six of the nine Tables P-VI through P-VII and P-X through P-XII wherein flocculants were tested (parts A and B of Tables P-X through P-XII being each counted as a table), the average water content for composite mixes containing flocculants were lower than the mixes not containing flocculants.

In the Tables below GSS means Ground Sodium Sulfate, SS means sodium sulfite/sulfate/carbonate as described above. The R following the column number indicates that the composite was permitted to set in the column for a period of time (on the order of 5 hours) before the column was put into test by loading with the water head.

                                      TABLE P-V                                    __________________________________________________________________________      98% FA + A/2% SODIUM SALTS                                                    __________________________________________________________________________     A. Columns Containing GSS                                                      COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SEC                                          __________________________________________________________________________     82 AFA-1                                                                              96.9                                                                              2.0                                                                               1.1 VOL                                                                               19.5 3     8.9 × 10.sup.-7                           134                                                                               AFA-2                                                                              88.1                                                                              2.0                                                                               10.0 DCS                                                                              25.8 2     9.4 × 10.sup.-7                           70 OFA-2                                                                              96.7                                                                              2.0                                                                               1.3 VOL                                                                               23.8 1     6.4 × 10.sup.-7                           76R                                                                               OFA-2                                                                              96.7                                                                              2.0                                                                               1.3 VOL                                                                               23.8 1     3.5 × 10.sup.-6                           __________________________________________________________________________     B. Columns Containing SS                                                       COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SEC                                          __________________________________________________________________________     118                                                                               AFA-2                                                                              95.6                                                                              1.9                                                                               2.5 VOL                                                                               27.3 2     6.2 × 10.sup.-7                           132                                                                               AFA-2                                                                              95.6                                                                              2.0                                                                               2.4 VOL                                                                               28.9 2     9.3 × 10.sup.-7                           133                                                                               AFA-2                                                                              94.5                                                                              1.9                                                                               3.6 VOL                                                                               30.6 2     4.1 × 10.sup.-7                           119                                                                               AFA-2                                                                              94.4                                                                              2.0                                                                               3.6 VOL                                                                               30.8 3     4.2 × 10.sup.-7                           151                                                                               AFA-2                                                                              88.2                                                                              1.9                                                                               9.9 VOL                                                                               26.1 2     7.4 × 10.sup.-7                           120                                                                               AFA-2                                                                              88.2                                                                              1.8                                                                               10.0 VOL                                                                              29.5 2     1.4 × 10.sup.-6                           __________________________________________________________________________

                                      TABLE P-VI                                   __________________________________________________________________________      95% FA + A/5% SODIUM SALTS                                                    __________________________________________________________________________     A. Columns Containing GSS                                                      COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SEC                                          __________________________________________________________________________      83                                                                               AFA-1                                                                              93.7                                                                              5.0                                                                               1.3 VOL                                                                               20.2 3     1.1 × 10.sup.-6                           104                                                                               AFA-1                                                                              93.0                                                                              5.0                                                                               2.0 VOL                                                                               19.8 1     3.8 × 10.sup.-7                           153                                                                               AFA-1                                                                              93.0                                                                              5.0                                                                               2.0 VOL                                                                               15.7 4     7.3 × 10.sup.-7                           105                                                                               AFA-1                                                                              92.0                                                                              5.0                                                                               3.0 VOL                                                                               20.4 1     9.3 × 10.sup.-7                           154                                                                               AFA-1                                                                              92.0                                                                              5.0                                                                               3.0 VOL                                                                               14.2 4     7.6 × 10.sup.-7                           135                                                                               AFA-2                                                                              85.5                                                                              4.5                                                                               10.0 DCS                                                                              24.8 2     1.2 × 10.sup.-6                           136                                                                               AFA-2                                                                              81.0                                                                              4.1                                                                               14.9 DCS                                                                              24.9 2     3.3 × 10.sup.-7                            71                                                                               OFA-2                                                                              93.8                                                                              5.0                                                                               1.3 VOL                                                                               23.8 1     6.4 × 10.sup.-7                            77                                                                               OFA-2                                                                              93.6                                                                              5.1                                                                               1.2 VOL                                                                               18.5 1     2.9 × 10.sup.-6                           114                                                                               KFA-1                                                                              91.4                                                                              5.0                                                                               3.6 VOL                                                                               20.7 1     1.9 ×  10.sup.-6                          115                                                                               KFA-1                                                                              90.1                                                                              5.1                                                                               4.8 VOL                                                                               21.0 3     2.5 × 10.sup.-6                           117                                                                               KFA-1                                                                              95.2                                                                              4.8                                                                               CAT-C  21.2 1     7.8 × 10.sup.-7                           141                                                                               KFA-1                                                                              80.9                                                                              4.1                                                                               15.0 KAN                                                                              19.9 2     6.9 × 10.sup.-7                           __________________________________________________________________________     B. Columns Containing SS                                                       COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SEC                                          __________________________________________________________________________      98                                                                               AFA-1                                                                              93.7                                                                              5.1                                                                               1.2 VOL                                                                               19.4 2     1.1 × 10.sup.-6                           121                                                                               AFA-2                                                                              92.6                                                                              4.9                                                                               2.5 VOL                                                                               28.4 2     5.9 × 10.sup.-7                           152                                                                               AFA-2                                                                              92.6                                                                              4.9                                                                               2.5 VOL                                                                               24.2 1     3.5 × 10.sup.-6                           122                                                                               AFA-2                                                                              91.6                                                                              4.8                                                                               3.6 VOL                                                                               29.5 2     1.3 × 10.sup.-6                           123                                                                               AFA-2                                                                              85.5                                                                              4.5                                                                               10.0 DCS                                                                              24.8 2     1.6 × 10.sup.-6                           124                                                                               AFA-2                                                                              81.0                                                                              4.1                                                                               14.9 DCS                                                                              24.9 2     7.3 × 10.sup.-7                           __________________________________________________________________________

                                      TABLE P-VII                                  __________________________________________________________________________      90% FA + A/10% SODIUM SALTS                                                   __________________________________________________________________________     A. Columns Containing GSS                                                      COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SEC                                          __________________________________________________________________________      84                                                                               AFA-1                                                                              89.0                                                                              9.8                                                                               1.2 VOL                                                                               19.4 3     9.5 × 10.sup.-8                            92                                                                               AFA-1                                                                              88.0                                                                              10.0                                                                              2.0 VOL                                                                               18.5 2     7.8 × 10.sup.-8                            93                                                                               AFA-1                                                                              86.4                                                                              10.6                                                                              3.0 VOL                                                                               20.1 5     3.1 × 10.sup.-8                           137                                                                               AFA-2                                                                              81.0                                                                              9.0                                                                               10.0 DCS                                                                              24.2 2     1.4 × 10.sup.-6                           138                                                                               AFA-2                                                                              76.5                                                                              8.5                                                                               15.0 DCS                                                                              24.6 2     7.9 × 10.sup.-7                            72                                                                               OFA-2                                                                              88.9                                                                              9.9                                                                               1.2 VOL                                                                               20.1 1     4.0 × 10.sup.-7                            78R                                                                              OFA-2                                                                              88.8                                                                              9.9                                                                               1.3 VOL                                                                               20.4 1     9.4 × 10.sup.-7                            81                                                                               KFA-1                                                                              88.9                                                                              9.9                                                                               1.2 VOL                                                                               22.4 1     3.6 × 10.sup.-6                           112                                                                               KFA-1                                                                              87.6                                                                              10.0                                                                              2.4 VOL                                                                               20.8 1     6.4 × 10.sup.-6                           113                                                                               KFA-1                                                                              86.3                                                                              10.0                                                                              3.7 VOL                                                                               21.1 1     1.9 × 10.sup.-6                           116                                                                               KFA-1                                                                              90.0                                                                              10.0                                                                              CAT-C  21.3 1     7.1 × 10.sup.-6                           142                                                                               KFA-1                                                                              76.5                                                                              8.3                                                                               15.0 KAN                                                                              19.9 2     4.3 × 10.sup.-7                           __________________________________________________________________________     B. Columns Containing SS                                                       COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SEC                                          __________________________________________________________________________     125                                                                               AFA-2                                                                              87.9                                                                              9.7                                                                               2.4 VOL                                                                               24.2 2     1.5 × 10.sup.-6                           139                                                                               AFA-2                                                                              87.9                                                                              9.7                                                                               2.4 VOL                                                                               26.1 2     7.6 × 10.sup.-7                           140                                                                               AFA-2                                                                              86.9                                                                              9.5                                                                               3.6 VOL                                                                               27.5 2     1.5 × 10.sup.-7                           126                                                                               AFA-2                                                                              86.8                                                                              9.5                                                                               3.7 VOL                                                                               26.4 2     2.3 × 10.sup.-7                           127                                                                               AFA-2                                                                              81.0                                                                              9.0                                                                               10.0 DCS                                                                              23.3 3     4.0 × 10.sup.-8                           128                                                                               AFA-2                                                                              76.6                                                                              8.4                                                                               15.0 DCS                                                                              23.0 3     4.4 × 10.sup.-7                            99                                                                               AFA-1                                                                              89.8                                                                              9.0                                                                               1.2 VOL                                                                               17.9 7     1.3 × 10.sup.-6                           __________________________________________________________________________

                                      TABLE P-VIII                                 __________________________________________________________________________      85% FA + A/15% SODIUM SALTS                                                   __________________________________________________________________________     A. Columns Containino GSS                                                      COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SEC                                          __________________________________________________________________________      85                                                                               AFA-1                                                                              84.0                                                                              14.8                                                                              1.2 VOL                                                                               19.3 3     3.1 × 10.sup.-8                            79R                                                                              OFA-2                                                                              84.0                                                                              14.7                                                                              1.1 VOL                                                                               21.5 1     1.5 × 10.sup.-7                            73                                                                               OFA-2                                                                              84.0                                                                              14.7                                                                              1.3 VOL                                                                               22.6 1     1.7 × 10.sup.-7                            87                                                                               OFA-2                                                                              80.0                                                                              15.0                                                                              5.0 KAN                                                                               22.9 1     3.2 × 10.sup.-6                            88                                                                               OFA-2                                                                              74.9                                                                              15.0                                                                              10.1 KAN                                                                              20.9 1     1.1 × 10.sup.-6                           108                                                                               OFA-2                                                                              70.2                                                                              14.9                                                                              14.9 KAN                                                                              23.7 2     1.5 × 10.sup.-6                           109                                                                               OFA-2                                                                              70.2                                                                              14.9                                                                              14.9 KAN                                                                              22.2 1     2.1 × 10.sup.-7                                        +CAT-C                                                            __________________________________________________________________________     B. Columns Containing SS                                                       COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SEC                                          __________________________________________________________________________     100                                                                               AFA-1                                                                              84.2                                                                              14.6                                                                              1.2 VOL                                                                               18.3 13    1.2 × 10.sup.-7                           129                                                                               AFA-2                                                                              82.9                                                                              14.6                                                                              2.5 VOL                                                                               23.3 7     7.2 × 10.sup.-8                           130                                                                               AFA-2                                                                              76.5                                                                              13.5                                                                              10.0 DCS                                                                              21.3 7     5.8× 10.sup.-7                            131                                                                               AFA-2                                                                              72.2                                                                              12.8                                                                              15.0 DCS                                                                              22.0 7     3.8 × 10.sup.-7                           __________________________________________________________________________

                                      TABLE P-IX                                   __________________________________________________________________________     80% FA + A/20% SODIUM SALTS (GSS)                                              COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SEC                                          __________________________________________________________________________     86 AFA-1                                                                              78.8                                                                              20.0                                                                              1.2 VOL                                                                               19.7 83    <10.sup.-7                                      75 OFA-2                                                                              78.7                                                                              20.0                                                                              1.3 VOL                                                                               21.0 7     8.9 × 10.sup.-8                           80R                                                                               OFA-2                                                                              78.7                                                                              20.0                                                                              1.3 VOL                                                                               21.5 5     1.8 × 10.sup.-8                           __________________________________________________________________________

                                      TABLE P-X                                    __________________________________________________________________________      55% FA + A/45% SODIUM SALTS                                                   __________________________________________________________________________     A. Columns Containing GSS                                                      COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SEC                                          __________________________________________________________________________     53 OFA-1                                                                              53.9                                                                              44.1                                                                              2.0 KAN                                                                               17.5 103   4.8 × 10.sup.-6                           54 OFA-1                                                                              52.2                                                                              42.8                                                                              5.0 KAN                                                                               19.4 131   <10.sup.-7                                      52 OFA-1                                                                              54.3                                                                              44.4                                                                              1.3 VOL                                                                               19.2 131   <10.sup.-7                                      51 OFA-1                                                                              55.0                                                                              45.0                                                                              CAT-LV 16.7 131   <10.sup.-7                                      62 OFA-1                                                                              55.0                                                                              45.0                                                                              CHEM   18.3 126   <10.sup.-7                                      69 OFA-1                                                                              55.0                                                                              45.0                                                                              CAT-C  20.0  90   <10.sup.-7                                      65 OFA-2                                                                              52.3                                                                              42.8                                                                              4.9 KAN                                                                               22.6  32   8.8 × 10.sup.-8                           __________________________________________________________________________     B. Columns Containing SS                                                       COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SE                                           __________________________________________________________________________     31 OFA-1                                                                              50.0                                                                              40.9                                                                              9.1 DCS                                                                                19.4                                                                               193   <10.sup.-7                                      30 OFA-1                                                                              52.4                                                                              42.8                                                                              4.8 DCS                                                                               19.4 193   <10.sup.-7                                      37 OFA-1                                                                              52.2                                                                              42.8                                                                              5.0 KAN                                                                               21.0 156   <10.sup.-7                                      36 OFA-1                                                                              53.9                                                                              44.1                                                                              2.0 KAN                                                                               20.1 156   <10.sup.-7                                      26 OFA-1                                                                              54.3                                                                              44.4                                                                              1.3 VOL                                                                               19.4 227   <10.sup.-7                                      27 OFA-1                                                                              54.3                                                                              44.4                                                                              1.3 VOL                                                                               19.4 227   <10.sup.-7                                                   +CAT-C                                                            25 OFA-1                                                                              55.0                                                                              45.0                                                                              CAT-LV 19.4 235   <10.sup.-7                                      33 OFA-1                                                                              55.0                                                                              45.0                                                                              CHEM   19.2 179   <10.sup.-7                                      22 OFA-1                                                                              55.0                                                                              45.0                                                                              PERCOL 18.5 247   <10.sup.-7                                      24 OFA-1                                                                              55.0                                                                              45.0                                                                              CAT-C  19.2 235   <10.sup.-7                                      64 OFA-2                                                                              52.3                                                                              42.8                                                                              4.9 KAN                                                                               22.9  90   <10.sup.-7                                      __________________________________________________________________________

                                      TABLE P-XI                                   __________________________________________________________________________      40%/FA + A/60% SODIUM SALTS                                                   __________________________________________________________________________     A. Columns Containing GSS                                                      COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SEC                                          __________________________________________________________________________     55 OFA-1                                                                              39.2                                                                              58.8                                                                              2.0 KAN                                                                               17.9 131   <10.sup.-7                                      56 OFA-1                                                                              38.0                                                                              57.1                                                                              4.9 KAN                                                                               17.1 131   <10.sup.-7                                      57 OFA-1                                                                              36.0                                                                              54.0                                                                              10.0 KAN                                                                              17.1 131   <10.sup.-7                                      59 OFA-1                                                                              39.4                                                                              59.3                                                                              1.3 VOL                                                                               17.1 131   <10.sup.-7                                      58 OFA-1                                                                              39.9                                                                              60.1                                                                              CAT-C  16.3 131   <10.sup.-7                                      67 OFA-2                                                                              38.0                                                                              57.0                                                                              5.0 KAN                                                                               19.0  90   <10.sup.-7                                      103                                                                               OFA-2                                                                              30.3                                                                              60.7                                                                              9.0 KAN                                                                               21.1  87   <10.sup.-7                                      __________________________________________________________________________     B. Columns Containing SS                                                       COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SEC                                          __________________________________________________________________________     40 OFA-1                                                                              36.0                                                                              54.0                                                                              10.0 KAN                                                                              20.1 156   <10.sup.-7                                      39 OFA-1                                                                              37.9                                                                              57.1                                                                              5.0 KAN                                                                               20.1 156   <10.sup.-7                                      38 OFA-1                                                                              39.2                                                                              58.8                                                                              2.0 KAN                                                                               20.7 156   <10.sup.-7                                      42 OFA-1                                                                              39.5                                                                              59.3                                                                              1.2 VOL                                                                               19.2 156   <10.sup.-7                                      41 OFA-1                                                                              40.0                                                                              60.0                                                                              CAT-C  21.0 156   <10.sup.-7                                      66 OFA-2                                                                              38.0                                                                              57.0                                                                              5.0 KAN                                                                               24.5  90   <10.sup.-7                                      __________________________________________________________________________

                                      TABLE P-XII                                  __________________________________________________________________________      25% FA + A/75% SODIUM SALTS                                                   __________________________________________________________________________     A. Columns Containinq GSS                                                      COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SEC                                          __________________________________________________________________________     101                                                                               OFA-2                                                                              24.7                                                                              74.3                                                                              1.0 VOL                                                                               22.4 88    <10.sup.-7                                      106                                                                               OFA-2                                                                              24.5                                                                              73.4                                                                              2.1 VOL                                                                               24.8 80    <10.sup.-7                                       97                                                                               OFA-2                                                                              24.5                                                                              73.6                                                                              1.9 VOL                                                                               22.0 77    <10.sup.-7                                      110                                                                               OFA-2                                                                              24.2                                                                              72.8                                                                              3.0 VOL                                                                               20.7 73    <10.sup.-7                                       90                                                                               OFA-2                                                                              23.7                                                                              71.3                                                                              5.0 KAN                                                                               19.5  0    >10.sup.-6                                      102                                                                               OFA-2                                                                              23.7                                                                              71.3                                                                              5.0 KAN                                                                               22.9  0    >10.sup.-6                                      107                                                                               OFA-2                                                                              21.3                                                                              63.7                                                                              15.0 KAN                                                                              23.5 24    4.9 × 10.sup.-7                           143                                                                               OFA-2                                                                              20.0                                                                              60.0                                                                              20.0 KAN                                                                              21.6 26    5.5 × 10.sup.-8                            91                                                                               OFA-2                                                                              25.0                                                                              75.0                                                                              CAT-C  19.5 77    <10.sup.-7                                      __________________________________________________________________________     B. Columns Containing SS                                                       COL                                                                               FLY ASH                                                                               GSS                                                                               ADDITIVE                                                                              WATER                                                                               DAYS  K-PERM                                          NO.                                                                               TYPE                                                                               %  %  %      %    NO LEAK                                                                              CM/SEC                                          __________________________________________________________________________     144                                                                               OFA-3                                                                              24.5                                                                              74.3                                                                              1.2 VOL                                                                               22.3 49    <10.sup.-7                                      145                                                                               OFA-3                                                                              23.1                                                                              74.5                                                                              2.4 VOL                                                                               23.3 49    <10.sup.-7                                      146                                                                               OFA-3                                                                              23.6                                                                              72.8                                                                              3.6 VOL                                                                               24.5 49    <10.sup.-7                                      148                                                                               OFA-3                                                                              23.8                                                                              71.2                                                                              5.0 KAN                                                                               24.7  0    >10.sup.-6                                      149                                                                               OFA-3                                                                              22.5                                                                              67.5                                                                              10.0 KAN                                                                              22.4 49    <10.sup.-7                                      150                                                                               OFA-3                                                                              24.2                                                                              61.4                                                                              14.4 KAN                                                                              23.1 49    <10.sup.-7                                      147                                                                               OFA-3                                                                              25.0                                                                              75.0                                                                              CAT-C  22.9  0    >10.sup.-6                                      __________________________________________________________________________

Table P-XIII below is a series of columns showing that the waste ash is not limited to fossil fuel fly or bottom ash from industrial or power plates, but may also be any municipal or industrial incinerator ash, or a calcium scrubber sludge containing fly ash. Note from columns 241, 242, 276, 279, 281, and 282, in Table P-I these ashes, like the power plant ashes or CO FGD waste, along are highly permeable.

Likewise, Table P-II above shows the addition of smectite clay or floc along is inadequate to improve the waste ashes to the standard of impermeability as defined herein.

In contrast, columns in Table XIII below show that the addition of SS (the Sodium Sulfate/Carbonate mix, e.g., spent Nahcolite as representative of the co-disposed component) does provide the requisite impermeability.

                                      TABLE P-XIII                                 __________________________________________________________________________     TESTS OF OTHER ASH SOURCES                                                                 SS %                                                               COL                                                                               FLY ASH  Na.sub.2 SO.sub.4                                                                   ADDITIVE                                                                              WATER                                                                               DAYS   K-PERM                                     NO.                                                                               TYPE**                                                                               %  /Na.sub.2 CO.sub.3                                                                  %      %    NO LEAK*                                                                              SM/SEC                                     __________________________________________________________________________     277                                                                               Scrb Sldg                                                                            50.0                                                                              46.3 None   25.1 I.S., 40                                                                              <10.sup.-7                                             /3.7                                                               278                                                                               OFA   42.9                                                                              28.6 1.2 Clay                                                                              26.8 I.S., 37                                                                              <10.sup.-7                                    Scrb Sldg                                                                            25.0                                                                              /2.3                                                               280                                                                               OFA   43.4                                                                              29.0 None   27.9 I.S., 37                                                                              <10.sup.-7                                    Scrb Sldg                                                                            25.3                                                                              /2.3                                                               285                                                                               I.A.  42.9                                                                              28.6 1.2 Clay                                                                              18.8 I.S., 19                                                                              <10.sup.-7                                    Scrb Sldg                                                                            25.3                                                                              /2.3                                                               286                                                                               I.A.  43.4                                                                              29.1 None   20.2 I.S., 19                                                                              <10.sup.-7                                    Scrb Sldg                                                                            25.3                                                                              /2.3                                                               291                                                                               I.A.  49.7                                                                              46.6 None   17.0 I.S., 16                                                                              <10.sup.-7                                             /3.7                                                               292                                                                               I.A.  56.9                                                                              38.4 1.6 Clay                                                                              18.1 I.S., 16                                                                              <10.sup.-7                                             /3.1                                                               __________________________________________________________________________      Notes:                                                                         Col 277  Sand in tube; no Bentonite on sides; all remaining columns have       sand in tube; Bentonite on sides                                               *I.S. means still in service without substantial leakage, the numbers          being the number of days since pressurization.                                 **I.A. = Incinerator Ash; Scrb Sldg = Calcium Scrubber Sludge            

It should be understood that various modifications within the scope of this invention can be made by one of ordinary skill in the art without departing from the spirit thereof. For example, Nahcolite and other sodium salts such as hydrated Na₂ CO₃, commercial sodium bicarbonate, dense or light soda ash, Trona, sodium sesquicarbonate, Wegscheiderite or the like, or mixtures thereof, may be used as the sodium salt component. We therefore wish our invention to be defined by the scope of the appended claims as broadly as the prior art will permit, and in view of this specification if need be. 

We claim:
 1. A method of preparing waste ash for disposal comprising the steps of:(a) providing a waste ash; (b) introducing a sodium oxide salt compound into said ash in the range of from about 5 to 85 weight % on a dry basis; (c) said sodium oxide salt compound being selected from Na₂ SO_(x) where x is 3 or 4, NaHCO₃, Na₂ CO₃, and mixtures thereof; (d) said sodium oxide compound and said ash comprising an ash/sodium oxide salt composite; and (e) adjusting the water content of said composite to have from about 15 to about 28% by weight water content to produce a substantially homogenous, substantially impermeable wetted composite mass in non-pellet form having a coefficient of permeability value below about 10⁻⁶ cm/sec suitable for substantially solid mass landfill disposal without heat sintering.
 2. A method as in claim 1 which includes the added step of:(a) mixing said composite with a source of smectite clay in an amount in the range of below about 5 weight percent dry basis, in the presence of sufficient water to produce an5 additive-enhanced wetted composite having said water content.
 3. A method as in claim 2 which includes the added step of:(a) permitting said wetted composite to swell for a holding period of time sufficient that swelling substantially ceases before disposal is completed.
 4. A method as in claim 2 wherein:(a) amount of water is an amount sufficient to produce a composite of dough-like texture.
 5. A method as in claim 2 wherein:(a) said wetted composite is let set for a time sufficient to achieve a penetration resistance of about 4.5 tons/sq.ft.
 6. A method as in claim 2 which includes the added step of:(a) disposing of said additive-enhanced composite in a compacted landfill.
 7. A method as in claim 2 wherein:(a) said waste ash consists essentially of incinerator ash, scrubber sludge, fly ash, bottom ash or mixtures thereof.
 8. A method as in claim 7 wherein:(a) said waste ash is a mixture of fly ash and bottom ash, and (b) said bottom ash is present in an amount of up to about 80% by weight of the waste ash mixture, and the balance is fly ash.
 9. A method as in claim 8 wherein:(a) said bottom ash comprises ash particles of size on the order of 60% by weight less than 10 U.S. standard sieve mesh.
 10. A method as in claim 3 wherein:(a) said hold time is on the order of 0.5-8 hours.
 11. A method as in claim 2 wherein:(a) at least a portion of said water content is achieved by adding water to at least one of said clay, said composite and said additive-enhanced composite.
 12. A method as in claim 11 wherein:(a) a substantial portion of the water required to be added to achieve said water content is added to said clay to form a clay slurry, and said slurry is added to said composite.
 13. A method as in claim 2 wherein:(a) said Na₂ SO_(x) is introduced in said waste ash by injection of a dry sodium sorbent into the flue gas duct of an installation burning a fuel or combustible waste.
 14. A method as in claim 13 wherein:(a) said dry sodium sorbent is selected from Nahcolite, sodium bicarbonate, soda ash, trona, sodium sesquicarbonate, Wegscheiderite, or mixtures thereof.
 15. A method as in claim 14 wherein:(a) said sodium sorbent is solution-mined Nahcolite.
 16. A method as in claim 1 wherein:(a) up to about 3% of said water is replaced by a flocculant in an amount of up to 1 dry weight percent of said mix.
 17. A method as in claim 2 wherein:(a) up to about 3% of said water is replaced by a flocculant in an amount of up to 1 dry weight percent of said mix.
 18. A method as in claim 2 wherein:(a) said smectite clay is present in an amount of up to about 3 weight %.
 19. A method as in claim 7 wherein said waste ash includes incinerator ash.
 20. A method as in claim 7 wherein said waste ash includes scrubber sludge.
 21. A method as in claim 20 wherein said scrubber sludge is calcium scrubber sludge containing fly ash. 